Dt a level edexcel- Machining processes - Sheet1 Flashcards
(23 cards)
Name all 5 processes
Milling/routing, drilling, stamping, pressing, turning
What is the process for drilling?
Making holes using a rotating cutting tool, often a twist drill, in a hand-operated drill or drilling machine.
What are the applications of milling/routing?
Decorative panels such as wall panels
What are the characteristics in milling/routing?
Slower process with precision cutting makes holes or channels
What are the advantages and disadvantages of milling/routing?
+Powerful
+Precise
+strong enough to cut through mild steel
-slower process
-tools are expensive
-can be broken easily
What are the applications of drilling?
Creating holes in various materials.
What are the characteristics of drilling?
Produces holes for items such as dowels, screws and fittings
What are the advantages and disadvantages of using a drilling process?
+Efficient hole creation in different materials.
- Limited to hole-making.
- May not suit all shapes.
What is the process of turning?
Performed on a metalworking or woodturning lathe. Mark on the centre of the wood so that the inside spindle and the tailstock can hold the timber. Dead centre is positioned right on the points marked. Headstock spins the timber. Chisel and roughing tools are used and held (using the tool rest to support it) by the operator close to the wood to chisel away wood, forming its desired shape.
What are the applications of turning?
Chess pieces, table legs
What are the characteristics of turning?
Rotational movement shapes material.
What are the advantages and disadvantages of turning?
+Versatility in shaping.
+ Applicable to metal and wood.
- Limited to rotational symmetrical shapes.
What is the process of stamping?
Uses a die with a stamping press to cut, emboss, or bend sheet metal into blanks or nets.
What are the applications of stamping?
Coins, bottle caps, car body panels, kitchen utensils
What are the characteristics of stamping?
Die-based metal manipulation.
What are the advantages and disadvantages of stamping?
Advantages of Stamping:
High speed and efficient for mass production
Consistent and accurate part quality
Low cost per part (at high volume)
Can cut, bend, or shape sheet metal
Minimal material waste
Disadvantages of Stamping:
High initial cost for dies
Limited to thin materials
Dies wear out and need maintenance
Hard to change design once die is made
What is the process of pressing?
Linked with stamping, forming flat metal pieces using 2 dies into more complex 3D product
What are the applications of pressing?
Creating complex metal shapes such as pans or car panels.
What are the characteristics of pressing?
Transformation of flat pieces into three-dimensional forms.
What are the advantages and disadvantages of pressing?
+Enables production of complex shapes.
- Thickness of the metal sheet limits the process.
Tips on how to tell which process should be used?
Understand a material’s compatibility, precision requirements, and shape complexity.
Choose the appropriate process for each material:
Choose milling for metal cutting, routing for wood/plastics, drilling for holes, turning for rotational symmetry, stamping for flat blanks, pressing for complex shapes.
What should be evaluated when choosing a process?
Evaluate based on material, production volume, and required precision to make informed choices.
